Direct Drive Variable Crimp On Flange Tool

ABSTRACT

A crimping assembly is provided for securing a cover part to a structural member. The crimping assembly includes a housing, a drive shaft disposed within the housing and rotatable in a first direction, and a first roller fixedly secured to the drive shaft and rotatable therewith. The crimping assembly also includes a slide shaft disposed within the housing and rotatable in a second direction. A second roller is fixedly secured to the slide shaft and rotatable therewith. A drive mechanism is operably coupled to the drive and slide shafts to roll the first and second rollers over the cover part to secure the cover part to the structural member. A coupling mechanism is operably connected between the drive shaft and the slide shaft to allow movement of the slide shaft towards and away from the drive shaft during operation of the crimping assembly to accommodate variations in flange thickness.

The invention relates to a crimping assembly for securing a cover partto a structural member along an opening of a motor vehicle. Moreparticularly, the invention relates to a crimping assembly having afirst roller and a second roller that moves relative to the first rollerto accommodate variations in structural member thickness.

SUMMARY

According to one aspect of the invention, a crimping assembly isprovided for securing a cover part to a structural member. The crimpingassembly includes a housing, a drive shaft disposed within the housingand rotatable in a first direction, and a first roller fixedly securedto the drive shaft and rotatable therewith. The crimping assembly alsoincludes a slide shaft disposed within the housing and rotatable in asecond direction. A second roller is fixedly secured to the slide shaftand rotatable therewith. A drive mechanism is operably coupled to thedrive and slide shafts to roll the first and second rollers over thecover part to secure the cover part to the structural member. A couplingmechanism is operably connected between the drive shaft and the slideshaft to allow movement of the slide shaft towards and away from thedrive shaft during operation of the crimping assembly to accommodatevariations in structural member thickness.

According to another aspect of the invention, a crimping assembly forsecuring a cover part to a structural member includes a housing, a driveshaft disposed within the housing and rotatable in a first direction,and a first roller fixedly secured to the drive shaft and rotatabletherewith. A slide shaft is disposed within the housing and is rotatablein a second direction. A second roller is fixedly secured to the slideshaft and is rotatable therewith. A slider is disposed within thehousing and fixedly secured to the slide shaft. The slider is movablerelative to the drive shaft to set the distance between the first andsecond rollers. A drive mechanism is operably coupled to the drive shaftto rotate the drive shaft in the first direction. A coupling mechanismis operably connected between the drive shaft and the slide shaft torotate the slide shaft in the second direction in response to rotationof the drive shaft in the first direction. The coupling mechanism allowsmovement of the second roller towards and away from the first rollerduring operation of the crimping assembly to accommodate variations instructural member thickness.

According to yet another aspect of the invention, a crimping assemblyfor securing a cover part to a structural member includes a housing, adrive shaft disposed within the housing and rotatable in a firstdirection, and a first roller fixedly secured to the drive shaft androtatable therewith. A slide shaft is disposed within the housing and isrotatable in a second direction. A second roller is fixedly secured tothe slide shaft and is rotatable therewith. A drive mechanism isoperably coupled to the drive and slide shafts for rotation of the firstand second rollers to secure the cover part to the structural member. Aslider is disposed within the housing and is fixedly secured to theslide shaft. The slider is movable relative to the drive shaft to setthe distance between the first and second rollers.

According to still another aspect of the invention, a crimping assemblyfor securing a cover part to a structural member includes a housing, adrive shaft disposed within said housing and rotatable in a firstdirection, and a first roller fixedly secured to the drive shaft androtatable therewith. A slide shaft is disposed within the housing androtatable in a second direction. A second roller is fixedly secured tothe slide shaft and rotatable therewith. A drive mechanism is retainedwithin the handle and operably coupled to the drive and slide shafts forrotation of the first and second rollers to secure the cover part to thestructural member. A swivel coupling is disposed between the housing andthe drive shaft to allow the housing to rotate 360 degrees relative tothe drive shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily appreciated as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings wherein:

FIG. 1 is a fragmentary perspective view of a motor vehicle including adoor for selectively closing an opening in a body portion;

FIG. 2 is a fragmentary perspective view of a crimping assemblyincluding a housing;

FIG. 3 is a top view of the crimping assembly;

FIG. 4 is a cross-sectional view of the crimping assembly;

FIG. 5 is a cross-sectional view of the crimping assembly includingalternative positions for a handle and pneumatic motor;

FIG. 6 is a fragmentary perspective view of the crimping assembly withthe housing removed;

FIG. 7 is an enlarged cross-sectional view of the housing of thecrimping assembly; and

FIG. 8 is a cross-sectional view of the crimping assembly depicting thehousing swiveling relative to the handle.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to FIG. 1, a motor vehicle 10 includes a body portion 12defining an access opening 14 to a passenger compartment 16. A door 18is pivotally coupled to the body portion 12 to selectively close theaccess opening 14. The body portion 12 includes a structural member 20extending out from the body portion 12 along at least a portion of aperiphery of the access opening 14. In one embodiment, the structuralmember 20 is a flange. It is, however, appreciated that the structuralmember 20 may be any of numerous structures.

A cover part 22 is secured to the flange 20 to provide an aestheticallypleasing appearance at the opening 14 when the door 18 is open. Thecover part 22 generally includes an internal metal component that ismolded inside a resilient outer component so that the metal component isnot visible when the cover part 22 is secured to the flange 20. Theouter component is formed from a rubber-like material that is used toseal the access opening 14 when the door 18 is closed thereagainst.

A crimping assembly, generally shown at 24, is provided to crimp thecover part 22 over the flange 20 to secure the cover part 22 thereto.More specifically, the cover part 22 includes spaced apart leg portionsthat are crimped against the flange 20 on either side thereof. Thecrimping assembly 24 applies a force inwardly against the cover part 22on either side thereof after the cover part 22 is positioned over theflange 20. The crimping assembly 24 squeezes the cover part 22 aroundthe flange 20.

Referring to FIGS. 2 through 4, the crimping assembly 24 includes ahousing or head, generally indicated at 26, defining an interior portion28. In one embodiment, the housing 26 includes a bottom cap 30, a firstcompartment 32, a second compartment 34, and a top cap 36. The bottomcap 30, first 32 and second 34 compartments, and the top cap 36 arearranged in a stacked configuration, and are formed such that theinterior portion 28 extends continuously from the bottom cap 30 to thetop cap 36. A plurality of bottom screws 38 threadably engages each ofthe bottom cap 30, the first 32 and second 34 compartments, and the topcap 36 to fixedly secure the housing 26 together as a single component.It is also appreciated that the housing 26 of the crimping assembly 24may be formed from less than or more than four components.

The top cap 36 of the housing 26 includes a leading surface 40 extendingbetween a pair of spaced apart first 42 and second 44 end walls. Theleading surface 40 defines an opening 46 and a slot 48 extendingtherethrough. The opening 46 and the slot 48 are spaced apart from oneanother along the leading surface 40 of the housing 26. It is, however,contemplated that the leading surface 40 may define a single elongatedopening in place of the separate opening 46 and the slot 48.

The crimping assembly 24 includes a handle 50 coupled to the housing 26.A drive mechanism 52 is housed within the handle 50. In one embodimentthe drive mechanism 52 is a pneumatic motor. The pneumatic motor 52 isoperably connected to a transmission including an output gear 54. Thepneumatic motor 52 is in communication with an air line 56 (shown inFIG. 1). The air line 56 receives compressed air from an air source anddelivers the compressed air to the handle 50. The pneumatic motor 52receives the compressed air and transforms the compressed air intorotation of the output gear 54. A trigger 58 is coupled to the handle50. Upon activation of the trigger 58, the pneumatic motor 52 isactuated to initiate powered operation of the crimping assembly 24.

It is contemplated that the drive mechanism 52 is not limited to thepneumatic motor. For instance, in one embodiment the drive mechanism 52could be an electric motor. And in another embodiment the drivemechanism 52 could be a battery, in which case the crimping assembly 24would be a cordless device.

Referring to FIG. 5, the handle 50 including the pneumatic motor ordrive mechanism 52 can be moved into various operating positionsrelative to the housing 26 to accommodate different flangeconfigurations along the access opening 14. It is appreciated that theoperating positions shown in FIG. 5 are exemplary and the particularposition of the handle 50 and pneumatic motor or drive mechanism 52relative to the housing 26 is not limited to the specific positionsillustrated in FIG. 5.

Referring to FIGS. 6 through 7, the crimping assembly 24 includes adrive shaft 60 operably connected to the output gear 54 and extendingthrough the opening 46 along the leading surface 40 of the top cap 36. Adrive gear 62 is fixedly secured to the drive shaft 60 at a locationspaced apart from the output gear 54. A first roller 64 is fixedlysecured to the drive shaft 60 at one end thereof by a roller screw 65. Aroller pad 66 is fixedly mounted to the first roller 64. Upon actuationof the pneumatic motor 52, the drive shaft 60 rotates in a firstdirection and urges the drive gear 62 and first roller 64 to rotatetherewith. A pair of support bearings 68, 70 is mounted along the driveshaft 60. One support bearing 68 is positioned adjacent the drive gear62 and another support bearing 70 is positioned adjacent the firstroller 64.

The crimping assembly 24 also includes a slide shaft 72 disposed withinthe housing 26 and spaced apart from the drive shaft 60. The slide shaft72 extends through the slot 48 formed along the leading surface 40 ofthe top cap 36. A second roller 74 is fixedly secured to the slide shaft72 by a roller screw 75. A roller pad 76 is fixedly mounted to thesecond roller 74. The slide shaft 72 rotates about a first axis ofrotation 73. The slide shaft 72 rotates in a second direction oppositethe first direction and urges the second roller 74 to rotate therewith.The slide shaft 72 is movable in the direction of arrows A and B to movethe second roller 74 towards and away from the first roller 64. A pairof spaced apart thrust washers 77, 79 is disposed along the slide shaft72.

A coupling mechanism, generally indicated at 78, is provided to operablycouple the slide shaft 72 to the drive shaft 60. The coupling mechanism78 includes a driven gear or input rotary member 80 in meshingengagement with the drive gear 62 such that rotation of the drive gear62 in one direction will rotate the driven gear 80 in an oppositedirection. The driven gear 80 is fixedly mounted along a driven shaft82. A support bearing 84 supports one end of the driven shaft 82. Thedriven gear 80 and the driven shaft 82 rotate about a second axis ofrotation 85. The second axis of rotation 85 is offset from the firstaxis of rotation of the slide shaft 72.

The coupling mechanism 78 also includes an intermediate rotary member 86having a ring-like configuration. The intermediate rotary member 86 isrotatably coupled to the driven gear 80 by a first set of link members88. More specifically, each one of the first set of link members 88includes one end rotatably coupled to the driven gear 80 and an opposingend rotatably coupled to the intermediate rotary member 86. The couplingof the intermediate rotary member 86 to the driven gear 80 allows theintermediate rotary member 86 to rotate about an axis that is offsetfrom the first 73 and second 85 axes of rotation.

The coupling mechanism 78 further includes an output rotary member 90that is rotatably coupled to the intermediate rotary member 86 by asecond set of link members 92. More specifically, each one of the secondset of link members 92 includes one end rotatably coupled to theintermediate rotary member 86 and an opposing end rotatably coupled tothe output rotary member 90. The coupling of the output rotary member 90to the intermediate rotary member 86 via the second set of link members92 allows the output rotary member to rotate about the first axis ofrotation 73. The slide shaft 72 is fixedly secured to the output rotarymember 90. As a result, the slide shaft 72 can rotate about the firstaxis of rotation 73 which is offset from the second axis of rotation 85.Thus, the coupling mechanism 78 provides for torque transfer from thedriven shaft 82 to the slide shaft 72 even though the driven 82 andslide 72 shafts rotate about different axes of rotation. Such a couplingmechanism is commonly referred to as a Schmidt coupling.

The crimping assembly 24 further includes a slider 94 disposed withinthe top cap 36 of the housing 26 and movable relative to the top cap 36in the direction of arrows A and B. The slider 94 includes a top surface96 and a bottom surface 98. The slider 94 also includes first 100 andsecond 102 side walls spaced apart from one another by the top 96 andbottom 98 surfaces. The slide shaft 72 is fixedly secured to the slider94 and extends through the top 96 and bottom 98 surfaces of the slider94. Adjustment screws 104, 106 each extend through the first end wall 42of the top cap 36 and into threaded engagement with the slider 94 at thefirst side wall 100 thereof. As a result, adjusting the adjustmentscrews 104, 106 causes the slider 94 to move relative to the housing 26.The movement of the slider 94 urges linear movement of the slide shaft72 relative to the drive shaft 60 in the direction of arrow A or B tomove the second roller 74 towards or away from the first roller 64. Thislinear movement of the slide shaft 72 is permitted by the configurationof the coupling mechanism 78. Access screws 108, 110 (shown in FIG. 2)are threaded onto one end of the respective adjustment screws 104, 106and provide access thereto. The access screws 108, 110 are removed whenadjustment of the second roller 74 is desired. The slider 94 includes anelongated shaft slot 112 formed along the top 96 and bottom 98 surfacesand extending therebetween. The drive shaft 60 is received within theelongated shaft slot 112. The elongated shaft slot 112 allows formovement of the slider 94 relative to the drive shaft 60.

The crimping assembly 24 includes biasing members 114, 116 that bias theslider 94 in the direction of arrow A, shown in FIG. 7, to urge thesecond roller 74 towards the first roller 64. Each biasing member 114,116 is received within the slider 94 at the second side wall 102thereof. Spring guide screws 118, 120 threadably engage the top cap 36and extend into the slider 94 to retain the biasing members 114, 116 inplace. The spring guide screws 118, 120 can be temporarily removed tofacilitate the replacement of the existing biasing members 114, 116 withbiasing members 114, 116 that exert more or less pressure. Because thecrimping assembly 24 may be used in widely varying operatingenvironments, there is no guarantee that the pressure delivered to thepneumatic motor 52 will remain consistent from time to time or place toplace. As such, the crimping assembly 24 allows users to address suchinconsistencies in pressure by determining the amount of pressure to beexerted by the biasing members 114, 116.

In operation, a user first establishes a minimum thickness of the flange20 to ensure retention of the crimping assembly 24 therealong. The useradjusts the distance between the first 64 and second 74 rollers, alsoknown as the pitch, so that the crimping assembly 24 at a start positionwill fit tightly around the flange 20. To adjust the pitch, the userremoves the access screws 108, 110 to access the adjustment screws 104,106. The user adjusts the adjustment screws 104, 106 to force the slider94 to move in the direction of arrow A or arrow B. The movement of theslider 94 moves the second roller 72 either towards or away from thefirst roller 64. Once the desired pitch is achieved, operation of thecrimping assembly 24 begins away from the flange 20 by squeezing thetrigger 58 to activate the pneumatic motor 52. The pneumatic motor 52causes rotation of the first roller 64 in a first direction via thedrive shaft 60. At the same time, the second roller 74 rotates in asecond direction via the coupling mechanism 78 and the slide shaft 72.The crimping assembly 24 is then brought to the flange 20 at a 45 degreeangle until the first 64 and second 74 rollers make contact with thecover part 22 and the crimping assembly 24 rolls thereon. The crimpingassembly 24 is rotated to a 90 degree angle relative to the flange 20and moves along the access opening 14 while securing the cover part 22to the flange 20. The crimping assembly 24 is eventually rotated back tothe 45 degree angle and the crimping assembly 24 rolls off the coverpart 22. The trigger 58 is then released to stop rotation of the first64 and second 74 rollers.

As the crimping assembly 24 is moved along the access opening 14 tocrimp the cover part 22 along the length of the flange 20, the couplingmechanism 78 allows the crimping assembly 24 to adjust to variation inthe thickness of the flange 20 without stopping operation of thecrimping assembly 24. If the thickness of the flange 20 increases at oneor more points along its length, the second roller 74 is able to moveaway from the first roller 64 to accommodate any variation in width.This functionality is provided by the coupling mechanism 78 which allowsthe slide shaft 72 to float, that is, to move towards and away from thedrive shaft 60 during operation of the crimping assembly 24. At the sametime, the biasing members 114, 116 bias the second roller 74 towards thefirst roller 64 to ensure a tight fit between the crimping assembly 24and the cover part 22. And in those instances when the thickness of theflange 20 decreases at one or more points along its length, the biasingmembers 114, 116 will bias the second roller 74 towards the first roller64 to ensure the same tight fit between the crimping assembly 24 and thecover part 22.

In order to adjust the pressure provided by the biasing members 114,116, the first 64 and second 74 rollers are first removed from therespective drive 60 and slide 72 shafts by removing the roller screws65, 75. The plurality of bottom screws 38 is then unscrewed to allowremoval of the top cap 36. The spring guide screws 118, 120 are removedand the slider 94 is removed from the top cap 36. The user is then ableto replace the existing biasing members 114, 116 with replacementbiasing members 114, 116 for lighter or heavier pressure.

Referring to FIG. 8, in another embodiment the housing 26 of thecrimping assembly 24 is able to swivel relative to the handle 50 toprovide additional flexibility during operation of the crimping assembly24. The crimping assembly 24 includes a swivel coupling 122 including aball bearing disposed between the drive shaft 60 and the housing 26. Theswivel coupling 122 allows the housing 26 to rotate 360 degrees relativeto the drive shaft 60.

The invention has been described in an illustrative manner. It is to beunderstood that the terminology, which has been used, is intended to bein the nature of words of description rather than of limitation. Manymodifications and variations of the invention are possible in light ofthe above teachings. Therefore, within the scope of the appended claims,the invention may be practiced other than as specifically described.

1. A crimping assembly for securing a cover part to a structural member,said crimping assembly comprising: a housing; a drive shaft disposedwithin said housing and rotatable in a first direction; a first rollerfixedly secured to said drive shaft and rotatable therewith; a slideshaft disposed within said housing and rotatable in a second direction;a second roller fixedly secured to said slide shaft and rotatabletherewith; a drive mechanism operably coupled to said drive and slideshafts for rotation of said first and second rollers to secure the coverpart to the structural member; and a coupling mechanism operablyconnected between said drive shaft and said slide shaft to allowmovement of said slide shaft relative to said drive shaft for movementof said second roller towards and away from said first roller in orderto accommodate variations in structural member thickness.
 2. Thecrimping assembly as set forth in claim 1 including a drive gearoperably coupled to said drive mechanism and fixedly secured to saiddrive shaft for rotation therewith in the first direction.
 3. Thecrimping assembly as set forth in claim 2 wherein said couplingmechanism includes a driven gear engageable with said drive gear andoperably coupled to said slide shaft.
 4. The crimping assembly as setforth in claim 3 wherein said coupling mechanism includes an outputrotary gear fixedly secured to said slide shaft and operably coupled tosaid driven gear.
 5. The crimping assembly as set forth in claim 4wherein said coupling mechanism includes an intermediate rotary gearoperably coupled between said driven gear and said output rotary gear.6. The crimping assembly as set forth in claim 5 wherein said couplingmechanism includes a first set of link members each having one endrotatably coupled to said driven gear and an opposing end rotatablycoupled to said intermediate rotary gear to rotate said intermediaterotary gear in response to rotation of said driven gear.
 7. The crimpingassembly as set forth in claim 6 wherein said coupling mechanismincludes a second set of link members each having one end rotatablycoupled to said intermediate rotary gear and an opposing end rotatablycoupled to said output rotary gear to rotate said output rotary gear inresponse to rotation of said intermediate rotary gear.
 8. The crimpingassembly as set forth in claim 3 including a slider fixedly secured tosaid slide shaft and movable therewith relative to said drive shaft toset the distance between said first and second rollers.
 9. The crimpingassembly as set forth in claim 8 including at least one biasing membercoupled to said slider to urge said second roller towards said firstroller to ensure a tight fit between said first and second rollers andthe cover part.
 10. The crimping assembly as set forth in claim 1including a handle fixedly secured to said housing and retaining saiddrive mechanism therein, said handle movable relative to said housinginto various operating positions to accommodate different structuralmember configurations.
 11. A crimping assembly for securing a cover partto a structural member, said crimping assembly comprising: a housing; adrive shaft disposed within said housing and rotatable in a firstdirection; a first roller fixedly secured to said drive shaft androtatable therewith; a slide shaft disposed within said housing androtatable in a second direction; a second roller fixedly secured to saidslide shaft and rotatable therewith; a slider disposed within saidhousing and fixedly secured to said slide shaft, said slider movablerelative to said drive shaft to set the distance between said first andsecond rollers; a drive mechanism operably coupled to said drive shaftto rotate said drive shaft in the first direction; and a couplingmechanism operably connected between said drive shaft and said slideshaft to rotate said slide shaft in the second direction in response torotation of said drive shaft in the first direction, said couplingmechanism allowing movement of said second roller towards and away fromsaid first roller during operation of said crimping assembly toaccommodate variations in structural member thickness.
 12. The crimpingassembly as set forth in claim 11 wherein said slide shaft rotates abouta first axis of rotation.
 13. The crimping assembly as set forth inclaim 12 wherein said driven gear rotates about a second axis ofrotation offset from said first axis of rotation.
 14. The crimpingassembly as set forth in claim 11 including at least one biasing memberhaving one end directly connected to said slider and an opposing enddirectly connected to said housing to urge said second roller towardssaid first roller to ensure a tight fit between said first and secondrollers and the cover part.
 15. A crimping assembly for securing a coverpart to a structural member, said crimping assembly comprising: ahousing; a drive shaft disposed within said housing and rotatable in afirst direction; a first roller fixedly secured to said drive shaft androtatable therewith; a slide shaft disposed within said housing androtatable in a second direction; a second roller fixedly secured to saidslide shaft and rotatable therewith; a drive mechanism operably coupledto said drive and slide shafts for rotation of said first and secondrollers to secure the cover part to the structural member; and a sliderdisposed within said housing and fixedly secured to said slide shaft,said slider movable relative to said drive shaft to set the distancebetween said first and second rollers.
 16. The crimping assembly as setforth in claim 15 including a drive gear fixedly secured to said driveshaft and operably coupled to said drive mechanism.
 17. The crimpingassembly as set forth in claim 16 including a driven gear in meshingengagement with said drive gear.
 18. The crimping assembly as set forthin claim 17 wherein said slide shaft is rotatable about a first axis ofrotation.
 19. The crimping assembly as set forth in claim 18 including adriven shaft fixedly secured to said driven gear, said driven shaftrotatable about a second axis of rotation offset from said first axis ofrotation.
 20. The crimping assembly as set forth in claim 15 includingat least one biasing member having one end directly connected to saidslider and an opposing end directly connected to said housing to urgesaid second roller towards said first roller to ensure a tight fitbetween said first and second rollers and the cover part.
 21. A crimpingassembly for securing a cover part to a structural member, said crimpingassembly comprising: a housing; a drive shaft disposed within saidhousing and rotatable in a first direction; a first roller fixedlysecured to said drive shaft and rotatable therewith; a slide shaftdisposed within said housing and rotatable in a second direction; asecond roller fixedly secured to said slide shaft and rotatabletherewith; a drive mechanism retained within said handle and operablycoupled to said drive and slide shafts for rotation of said first andsecond rollers to secure the cover part to the structural member; and aswivel coupling disposed between said housing and said drive shaft toallow said housing to rotate 360 degrees relative to said drive shaft.